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Supplement Guide - S1400CW: Site Considerations For Equipment Installation, Grounding & Wiring
Supplement Guide - S1400CW: Site Considerations For Equipment Installation, Grounding & Wiring
Issue: 04/05
TM
SITE CONSIDERATIONS
For
EQUIPMENT INSTALLATION,
GROUNDING
&
WIRING
Bristol Babcock
NOTICE
Copyright Notice
The information in this document is subject to change without notice. Every effort has been
made to supply complete and accurate information. However, Bristol Babcock assumes no
responsibility for any errors that may appear in this document.
TITLE
PAGE #
Section 1 - INTRODUCTION
1.1
1.2
Section 2 - PROTECTION
2.1
2.1.1
2.2
2.2.1
2.2.2
2.3
OVERVIEW ....................................................................................................................5-1
INSTRUMENT WIRING. .............................................................................................. 5-1
Common Returns ............................................................................................................5-1
Supplement S1400CW
Page 0-1
Table Of Contents
TITLE
PAGE #
REFERENCE DOCUMENTS
1.
2.
3.
4.
5.
6.
7.
IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems - ANSI/IEEE Std
142-1982
IEEE Guide for the Installation of Electrical Equipment to Minimize Electrical Noise inputs to Controllers
from External Sources - IEE Std 518-1982
Lightning Strike Protect; Roy B. Carpenter, Jr. & Mark N. Drabkin, Ph.D.; Lightning Eliminators &
Consultant, Inc., 6687 Arapahoe Road, Boulder Colorado
Lightning Protection Manual for Rural Electric Systems, NRECA Research Project 82-5, Washington DC,
1983
Grounding for the Control of EMI; Hugh W. Denny; Don White Consultants, Inc., 1983, 1st Edition
Fundamentals of EGM - Electrical Installations; Michael D. Price; NorAm Gas Transmission, 525 Milam
Street, Shreveport, Louisiana 71151
TeleFlow Modem Grounding Kit 621495-01-8 Installation Instructions - PIP-3530MGKI; Bristol Babcock,
Watertown, CT 06795
Supplement S1400CW
Page 0-2
Table Of Contents
Section 1 - Overview
1.1 INTRODUCTION
This document provides information pertaining to the installation of ControlWave
systems; more specifically, information covering reasons, theory and techniques for
protecting your personnel and equipment from electrical damage. Your instrument system
affects the quality of service provided by your company and many aspects of its operational
safety. Loss of instruments means lost production and profits as well as increased expenses.
Information contained in this document is for educational purposes. Bristol Babcock makes
no warranties or guarantees on the effectiveness or the safety of techniques described herein.
Where the safety of installations and personnel is concerned, refer to the National Electrical
Code Rules and rules of local regulatory agencies.
Section 2 - Protection
This section provides the reasons for protecting instrument systems. An overview of the
definition of quality and what we are trying to accomplish in the protection of site
installations and how to satisfy the defined requirements is presented. Additionally,
this section provides considerations for the protection of personnel and equipment.
Section 1 - Overview
Page 1-1
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Section 2 - Protection
2.1 PROTECTING INSTRUMENT SYSTEMS
Electrical instrumentation is susceptible to damage from a variety of natural and man
made phenomena. In addition to wind, rain and fire, the most common types of system and
equipment damaging phenomena are lightning, power faults, communication surges &
noise and other electrical interferences caused by devices such as radios, welders,
switching gear, automobiles, etc. Additionally there are problems induced by geophysical
electrical potential & noise plus things that are often beyond our wildest imagination.
2.1.1 Quality Is Conformance To Requirements
A quality instrumentation system is one that works reliably, safely and as purported by the
equipment manufacturer (and in some cases by the system integrator) as a result of good
equipment design and well defined and followed installation practices. If we except the
general definition of quality to be, quality is conformance to requirements, we must also
except the premise that a condition of quality cant exist where requirements for such an
end have not been evolved. In other words, you cant have quality unless you have
requirements that have been followed. By understanding the requirements for a safe, sound
and reliable instrumentation system, and by following good installation practices (as
associated with the personnel and equipment in question), the operational integrity of the
equipment and system will be enhanced.
Understanding what is required to properly install BBI equipment in various environments, safely, and in accordance with good grounding, isolating and equipment
protection practices goes a long way toward maintaining a system which is healthy to the
owner and customer alike. Properly installed equipment is easier to maintain and operate,
and is more efficient and as such more profitable to our customers. Following good installation practices will minimize injury, equipment failure and the customer frustrations
that accompany failing and poorly operating equipment (of even the finest design). Additionally, personnel involved in the installation of a piece of equipment add to or subtract
from the reliability of a system by a degree which is commensurate with their technical
prowess, i.e., their understanding of the equipment, site conditions and the requirements
for a quality installation.
Section 2 - Protection
Page 2-1
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Guide
Indoor or outdoor Dress Appropriately
If outdoor, what kind of environment, terrain, etc. Watch out for local varmint (bees,
spiders, snakes, etc.)
If indoor or outdoor determine if there are any pieces of dangerous equipment or any
processes which might be a risk to your safety
If in a tunnel, bunker, etc. watch out for a build up of toxic or flammable gases. Make
sure the air is good. Watch out for local varmint (bees, spiders, snakes, etc.)
Hazardous or Non-Hazardous Environment Wear appropriate safety equipment and
perform all necessary safety measures.
Before installing any equipment or power or ground wiring, make sure that there are no
lethal (life threatening) voltages between the site where the instrument will be installed
and other equipment, pipes, cabinets, etc. or to earth itself.
Never assume that adjacent or peripheral equipment has been properly installed and
grounded. Determine if this equipment and the ControlWave unit in question can be
touched simultaneously without hazard to personnel and/or equipment?
Before embarking to remote locations where there are few or no human inhabitants ask a
few simple questions like, should I bring water, food, hygienic materials, first aid kit, etc?
Be Prepared!
Observe the work habits of those around you for your own safety!
Some of the items that a service person should consider before ever going on site can be
ascertained by simply asking questions of the appropriate individual. Obviously other
safety considerations can only be established at the installation site.
Guide
Environment - Class I, Division 2 - Nonincendive
Environment - Class I, Division 1 - Intrinsically Safe
Other - Safe or unrated area
Earth Ground - Established by mechanical/electrical or
(both) or not at all.
Is the area prone to lightning strikes?
Are there surge suppressors installed or to be installed?
Are there overhead or underground power or communication cables in the immediate area?
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Page 2-2
Reference Section
See Appendix A of CI Manual
See Appendix B of CI Manual
See Section 3
See Section 4
See Section 4
See Section 2.3
Section 2 - Protection
2.3
Guide
Is there an antenna in the immediate area?
How close is other equipment? Can someone safely touch this
equipment and a ControlWave simultaneously?
Determine equipment ground requirements. How will the
ControlWave and its related wiring be grounded? Consider Earth
Ground, Circuit Ground, Conduit Ground, Site Grounds!
Are there any obviously faulty or questionable power or ground
circuits?
Reference Section
See Section 4.1.2
See Section 2.3
See Section 3
See Section 2.3
Section 2 - Protection
Page 2-3
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Page 3-1
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not be suitable for a complex system of sophisticated electronic equipment. Conditions such
as soil type, composition and moisture will all have a bearing on ground reliability.
A basic ground consists of a 3/4-inch diameter rod with a minimum 8-foot length driven into
conductive earth to a depth of about 7-feet as shown in Figure 3-1. Number 3 or 4 AWG
solid copper wire should be used for the ground wire. The end of the wire should be clean,
free of any coating and fastened to the rod with a clamp. This ground connection should be
covered or coated to protect it from the weather and the environment.
Good
Damp Loam
Salty Soil or Sand
Farm Land
Poor
Back Fill
Dry Soil
Sand Washed by a Lot of Rain
Dry Sand (Desert)
Rocky Soil
Ground Beds must always be tested for conductivity prior to being placed into service. A
brief description of ground bed testing in Good Soil and Poor Soil is provided herein.
Details on this test are described in the National Electrical Code Handbook. Once a reliable
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Page 3-2
ground has been established, it should be tested on a regular basis to preserve system
integrity.
Figure 3-3 - Basic Ground Bed Soil Test Setup with Additional Ground Rods
Figure 3-2 shows the test setup for Good Soil conditions. If the Megger* reads less than 5
ohms, the ground is good. The lower the resistance, the better the earth ground. If the
Section 3 - Grounding & Isolation
Page 3-3
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Megger reads more than 10 ohms, the ground is considered poor. If a poor ground is
indicated, one or more additional ground rods connected 10 feet from the main ground rod
should be driven into the soil and interconnected via bare AWG 0000 copper wire and 1 x
-20 cable clamps as illustrated in Figure 3-3). * Note: Megger is a Trademark of the
Biddle Instrument Co. (now owned by AVO International). Other devices that
may be used to test ground resistance are Viboground; Associated Research,
Inc., Groundmeter; Industrial Instruments, Inc., and Ground-ohmer; Herman
H. Sticht Co., Inc.
If the Megger still reads more than 10 ohms, mix a generous amount of cooking salt, ice
cream salt or rock salt with water and then pour about 2.5 to 5 gallons of this solution
around each rod (including the test rods). Wait 15 minutes and re-test the soil. If the test
fails, the soil is poor and a Poor Soil Ground Bed will have to be constructed.
Figure 3-4 shows a typical Poor Soil Ground Bed Electrode. A Poor Soil Ground Bed will
typically consists of four or more 10-foot long electrodes stacked vertically and separated by
earth. Figure 3-5 shows the construction of a Poor Soil Ground Bed. For some poor soil
sites, the ground bed will be constructed of many layers of Capacitive Couplings as
illustrated. In extremely poor soil sites one or more 3 by 3 copper plates (12 gauge or 1/16
thick) will have to be buried in place of the electrodes.
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Page 3-4
Page 3-5
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Page 3-6
For applications employing equipment that communicates over telephone lines, a lightning
arrester Must Be provided. For indoor equipment the lightning arrester must be installed
at the point where the communication line enters the building as shown in Figure 3-6. The
ground terminal of this arrester must connect to a ground rod and/or a buried ground bed.
Gas lines also require special grounding considerations. If a gas meter run includes a
thermocouple or RTD sensor installed in a thermowell, the well (not the sensor) must be
connected to a gas discharge-type lightning arrester as shown in Figure 3-7. A copper braid,
brazed to the thermal well, is dressed into a smooth curve and connected to the arrester as
shown. The curve is necessary to minimize arcing caused by lightning strikes or high static
surges. The path from the lightning arrester to the ground bed should also be smooth and
free from sharp bends for the same reason.
Page 3-7
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grounded to the pipeline. If any pressure transmitters or pulse transducers are remotely
mounted, connect their chassis grounds to the pipeline or earth ground.
Page 3-8
all conductive tubing that runs between the pipeline and mounting valve manifold
and/or the units multivariable pressure transducer
all conductive connections or tubing runs between the ControlWave EFM/GFC and
turbine meter, pulse transducer, or any input other device that is mounted on the
pipeline
any Temperature Transducer, Pressure Transmitter, etc. and their mount/interface to
the pipeline
Page 3-9
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See BBI Specification Summary F1670SS-0a for information on PGI Direct Mount Systems
and Manifolds.
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Page 3-10
Figure 4-1 - Average Thunderstorm Days of the Year (for Continental USA)
Section 4 - Lightning & Surge
Page 4-1
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Thunderstorms are cloud formations that produce lightning strikes (or strokes). Across the
United States there is an average of 30 thunderstorm days per year. Any given storm may
produce from one to several strokes. Data on the subject indicates that for an average area
within the United States there can be eight to eleven strokes to each square mile per year.
The risk of stroke activity is increased for various areas such central Florida where up to 38
strokes to each square mile per year are likely to occur.
To determine the probability of a given structure (tower, building, etc.) (within your
location) being struck, perform the following computation:
1. Using the map of Figure 4-1 (or a comparable meteorological map for your local), find
the Isokeraunic level (I) for your area. Then using Chart 1, find A for your area.
2. Refer to Figure 4-1 to find the latitude. Then using Chart 2, find B for your latitude
(Lat.).
3. Multiply A x B to get C.
4. To calculate the number of lightning strikes per year that are likely to strike a given
object (tower, mast, etc.), use the equation that follows (where C was calculated in
step 3 and H is equal to the height of the object.
Strikes Per Year = (C x H2) (.57 x 106 )
Chart 1
I
5
10
20
30
40
50
60
70
80
90
100
A
8
26
85
169
275
402
548
712
893
1069
1306
Chart 2
LAT.
25
30
35
40
45
B
.170
.200
.236
.280
.325
For Example: On Long Island, New York (Isokeraunic number 20), Chart 1 gives A to
equal 85. The latitude is approximately 40. Referring to Chart 2, B is found to be equal to
.28. C for this example is equal to 23.80. Using the equation for strikes per year, it is
determined that a 100-foot tower has .4 chances per year of being struck by lightning.
Assuming that no other structures are nearby, the tower will more than likely be struck by
lightning at least once in three years.
Note: The Isokeraunic activity numbers connoted as I, A and B in Charts 1 and 2 above
are provided for the continental United States. Isokeraunic data for various countries
is available from various federal or state Civil Engineering or Meterorelogical
organizations. This information is typically available from manufacturers of lightning
strike protection equipment (such as Lightning Arresters).
Since ControlWave, ControlWave MICRO, ControlWave EFM/GFC/XFC, ControlWaveLP and ControlWaveEXP units are dc operated systems that are isolated from AC
grids, they are typically immune to lightning strikes to power lines or power equipment
(except for inductive flashover due to close installation proximity). However, once a radio or
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Page 4-2
Page 4-3
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Page 4-4
communication equipment lightning arresters and surge suppressors should be tied to the
same system ground. System ground consists of the tower leg grounds utility ground and
bulkhead-equipment ground-stakes that are tied together via bare copper wire.
Page 4-5
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Page 4-6
Page 5-1
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Figure 5-1 - Field Wired Circuits With & Without A Common Return
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Page 5-2
Page 5-3
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Remember loose connections, bad connections, intermittent connections, corroded connections, etc., are hard to find, waste time, create system problems and confusion in addition to
being costly.
Page 5-4
Discharge Units should be placed on the base of the antenna and at the point where the
antenna lead (typically coax) enters the site equipment building. When a modem is used, a
lightning arrester should be placed at the point where the phone line enters the site
equipment building. If you use a modem (manufactured by other than BBI) it is
recommended that you also install a surge suppressors or lightning arrester on the phone
line as close to the modem as possible. Any unit interfaced to a radio or modem must be
connected to a known good earth ground.
Page 5-5
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BLANK PAGE
Bristol Babcock
1100 Buckingham Street
Watertown, CT 06795
Phone: +1 (860) 945-2200
Fax: +1 (860) 945-2213
Website: www.bristolbabcock.com
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Helicoid Instruments
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Phone: +1 (860) 945-2218
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Communications
Technology Group
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234 Attwell Drive
Toronto, Ont. M9W 5B3
Canada
PH: 416-675-3820
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info@bristolbabcock.ca
Mexico
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Homero No. 1343, 3er Piso
Col. Morales Polanco
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Mexico
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PH: +44 (0) 1905 856950
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enquiries@bristol-babcock.com
Asia Pacific
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PO Box 1987
Bunbury, Western Australia
6231
PH: +61 (0) 8 9791 3654
FAX: +61 (0) 8 9791 3173
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Bristol Babcock, Canada
3812 Edmonton Trail N.E.
Calgary, Alberta T2E 5T6
Canada
PH: 403-265-4808
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RC Rev: 05-Feb-04
Villahermosa Office
BBI, S.A. de C.V.
Av. Plomo No.2
Bodega No. 1 - Ciudad
Industrial
Villahermosa, Tabasco 86010
Mexico
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FAX: 52-993-353-3145
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United Kingdom
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enquiries@bristol-babcock.com